Gas-Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONS
CWI Series
Models
These instructions must be affixed on or adjacent to the boiler
Table of Contents
I Product Description
TABLE 1 CWI SPECIFICATIONS
II Specifications
FIGURE 1 CWI BOILERS - GENERALCONFIGURATION
III Before Installing
IV Locating the Boiler
V Air for Combustion and Ventilation
Example
For Buildings of Other than Unusually Tight Construction
ForBuildingsofUnusuallyTightConstruction
FIGURE 5 ALL AIR FROM OUTDOORS VIA VENTILATED ATTIC
FIGURE3BOILERINSTALLEDINCONFINEDSPACE, ALL AIR FROM INSIDE
FIGURE 4 ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC
FIGURE 6 ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM
VI Venting
Removing an Existing Boiler from a Common Chimney
FIGURE8 CWI BOILERTYPICALVENTSYSTEM INSTALLATION AND COMPONENTS
FIGURE 9 VENT DAMPER INSTALLATION DETAILS
VII Gas Piping
DANGER
VIII System Piping
StandardPiping
1413
Piping for Special Situations
FIGURE 11 STANDARD BOILER PIPING FIGURE 12 INDIRECT WATER HEATER
BOILERSIDEPIPING
FIGURE13 BOILERBYPASSPIPING
FIGURE14 ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER
FIGURE15 BOILERPIPINGWITHCHILLER
IX TANKLESS HEATER PIPING
FIGURE 17TANKLESSHEATERPIPING
A mixing valve does not eliminate the risk of scalding
Feel water before showering or bathing
IX Wiring
SingleZoneWiring
FIGURE 20 WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER
Wiring Variations
FIGURE 22 CIRCULATOR ZONEWIRING USING HONEYWELLR845As
FACTORY BOILER WIRING NOT SHOWN - SEE FIGURES 18
FIGURE23ZONEWIRINGUSINGHONEYWELLV8043FZONEVALVES
FACTORYWIRING NOT SHOWN - SEE FIGURES 18
Sequence of Operation, Standing Pilot, With Tankless Heater
CWI Control System - Sequence of Operation
Sequence of Operation, Standing Pilot, Less Tankless Heater
Sequence of Operation, Intermittent Ignition, Less Tankless Heater
Sequence of Operation, Intermittent Ignition, With Tankless Heater
XI Start-up and Checkout
Safety Control Operation - Standing Pilot and Intermittent Ignition
2726
FIGURE 24 STANDING PILOT BURNER FLAME
Page
Page
FOR YOUR SAFETY READ BEFORE OPERATING
LIGHTING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL
FOR YOUR SAFETY READ BEFORE LIGHTING
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW
7000ERHC SERIES GAS VALVES STANDING PILOT
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE LIGHTING
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
VR8204 AND VR8304 SERIES GAS VALVES INTERMITTENT PILOT
7000DERHC SERIES GAS VALVES INTERMITTENT PILOT
FOR YOUR SAFETY READ BEFORE LIGHTING
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
FIGURE 27a GASVALVEDETAIL-HONEYWELLVR8200ORVR8300STANDINGPILOT
FIGURE 28b GASVALVEDETAIL-ROBERTSHAW 7000DERHC INTERMITTENT IGNITION
XI Service and Maintenance
Heat Exchanger Cleaning Procedure
XIII Troubleshooting
START
C1&C2?
5&6 on
National Fuel Gas Code
National Fuel Gas Code
START
L2 ?
C2 and
C1&C2?
T&TV?
Standing Pilot Ignition System Troubleshooting Chart
Caution Read page 36 before attempting to use this chart
START
Intermittent Ignition System Troubleshooting Chart
Caution Read page 36 before attempting to use this chart
XIV PARTS
Page
These Valves Piped in Series to Provide Redundent Shut-off
1/4 Pilot Tubing Used with Robertshaw Valves
KEY #
40mm BURNERS ONLY
Page
KEY #
Page
Appendix A Knockdown Boiler Assembly Instructions
A. Before Installing
B. BaseAssembly Preparation
C. Heat Exchanger and Flue Collector Installation
FIGUREA1 BASE, HEAT EXCHANGER, FLUE COLLECTORASSEMBLY
D. Gas Valve Installation
E. Control and Trim Installation
FIGURE A2 JACKET INSTALLATION
F. Electrical Wiring Connections
G. Complete Installation
FIGURE A3 TAPPING LOCATIONS SEE TEXT FOR TAPPING USES
Manufacturer of Hydronic Heating Products
P.O. Box
3633 I. Street
Philadelphia
